Method of inspecting threaded fasteners and a system therefor

Abstract

The present invention relates to novel automated inspection systems and related methods of use. In particular, the present invention provides an automated threaded fastener inspection system, and related methods of use. Furthermore, the present invention provides systems and methods for identifying damaged threaded fasteners prior to industrial use.

1. A threaded fastener inspection system comprising:
 a light source; 
 a light shield; 
 a reflector having an opening therein for receiving a threaded fastener having a head, wherein said light shield and said reflector are positioned to direct light from said light source so that said threaded fastener head is back-lit; 
 an imaging device positioned to produce a back-lit image of said threaded fastener head. 
 
   
   
     2. The system of  claim 1 , wherein said reflector comprises a sleeve that receives said threaded fastener, wherein said sleeve supports said threaded fastener head over said reflector. 
   
   
     3. The system of  claim 1 , wherein said light source comprises a circular array of light emitting diodes. 
   
   
     4. The system of  claim 3 , wherein said circular array of light emitting diodes is positioned with respect to said light shield so that said threaded fastener head is shielded from being substantially directly illuminated by said circular array of light emitting diodes. 
   
   
     5. The system of  claim 1 , wherein said light shield is conical in shape. 
   
   
     6. The system of  claim 1 , wherein said reflector is formed from a polymeric material. 
   
   
     7. The system of  claim 1 , wherein said reflector comprises Delran. 
   
   
     8. The system of  claim 1 , further comprising a plurality of said reflectors. 
   
   
     9. The system of  claim 8 , wherein said plurality of reflectors are arranged in a rotating tray. 
   
   
     10. The system of  claim 1 , wherein said light source and said light shield are movably mounted so that said light shield and said light source can be raised and lowered over said reflector. 
   
   
     11. The system of  claim 1 , wherein said imaging device is a digital camera. 
   
   
     12. The system of  claim 11 , wherein said digital camera comprises a processor. 
   
   
     13. The system of  claim 12 , wherein said processor is configured to analyze images captured by said digital camera. 
   
   
     14. The system of  claim 1 , further comprising a thread damage inspection system. 
   
   
     15. A threaded fastener inspection system comprising:
 a light source comprising a circular array of light emitting diodes; 
 a light shield; 
 a reflector having a sleeve therein for receiving a threaded fastener having a head, wherein said sleeve supports said threaded fastener head over said reflector, wherein said light shield and said reflector are positioned to direct light from said light source so that said threaded fastener head is back-lit, and wherein said circular array of light emitting diodes is positioned over said light shield so that said head of said threaded fastener is shielded from being substantially directly illuminated by said circular array of light emitting diodes; 
 an imaging device positioned to capture a back-lit image of said threaded fastener head, wherein said imaging device comprises a processor configured to analyze images captured by said imaging device. 
 
   
   
     16. A method of identifying damaged threaded fasteners comprising:
 providing at least one threaded fastener having a head and an imaging device; 
 back-lighting said head of said threaded fastener; 
 obtaining a back-lit image of said head of said threaded fastener; and 
 analyzing said back-lit image of said head of said threaded fastener to detect damaged threaded fastener heads. 
 
   
   
     17. The method of  claim 16 , further comprising the step of sorting damaged threaded fastener heads from non-damaged threaded fastener heads. 
   
   
     18. The method of  claim 16 , wherein said imaging device is a digital camera. 
   
   
     19. The method of  claim 16 , wherein said imaging device comprises a processor. 
   
   
     20. The method of  claim 19 , wherein said processor is configured to identify the center of said head of said threaded fastener, measure a plurality of radii from said center, and compare said measurements to pre-determined values to identify damaged threaded fastener heads. 
   
   
     21. The method of  claim 20 , wherein said processor is further configured to compare an overlapping series of averaged radii measurements to pre-determined values to identify damaged threaded fastener heads.